EP3863827B1 - Verfahren und system zur herstellung einer gehäusevorrichtung - Google Patents

Verfahren und system zur herstellung einer gehäusevorrichtung Download PDF

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Publication number
EP3863827B1
EP3863827B1 EP19783069.8A EP19783069A EP3863827B1 EP 3863827 B1 EP3863827 B1 EP 3863827B1 EP 19783069 A EP19783069 A EP 19783069A EP 3863827 B1 EP3863827 B1 EP 3863827B1
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EP
European Patent Office
Prior art keywords
data
component
precursor
prediction model
charge
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EP19783069.8A
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English (en)
French (fr)
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EP3863827A1 (de
Inventor
Sairam POTARAJU
Reinhard Albers
Andreas Lyding
Michael LOOF
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Covestro Intellectual Property GmbH and Co KG
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Covestro Intellectual Property GmbH and Co KG
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Publication of EP3863827A1 publication Critical patent/EP3863827A1/de
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/76—Measuring, controlling or regulating
    • B29C45/766—Measuring, controlling or regulating the setting or resetting of moulding conditions, e.g. before starting a cycle
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/18—Filling preformed cavities
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/60—Measuring, controlling or regulating
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B13/00—Adaptive control systems, i.e. systems automatically adjusting themselves to have a performance which is optimum according to some preassigned criterion
    • G05B13/02—Adaptive control systems, i.e. systems automatically adjusting themselves to have a performance which is optimum according to some preassigned criterion electric
    • G05B13/04—Adaptive control systems, i.e. systems automatically adjusting themselves to have a performance which is optimum according to some preassigned criterion electric involving the use of models or simulators
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
    • B29C2945/76—Measuring, controlling or regulating
    • B29C2945/76451—Measurement means
    • B29C2945/76461—Optical, e.g. laser
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
    • B29C2945/76—Measuring, controlling or regulating
    • B29C2945/76929—Controlling method
    • B29C2945/76936—The operating conditions are corrected in the next phase or cycle
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/1204—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements and giving the material during expanding the shape of a particular article to be supported, e.g. a human body-part
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2075/00—Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0012—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular thermal properties
    • B29K2995/0015—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/762—Household appliances

Definitions

  • the invention is directed at a method for improving the production of a cased device.
  • Such cased devices or devices with a case are home appliances.
  • Home appliances and in particular refrigerators comprise casing components which serve both to provide mechanical stability and also temperature isolation.
  • Such casing components are regularly produced by foam injection molding into the appropriate cavity formed by the casing component.
  • the cavity may be formed by a shell of the casing component.
  • the shell may be a shell of a door or of a cabinet wall of the home appliance.
  • a common sort of product defect for such products can result from uneven or incomplete distribution of the foam within the cavity.
  • Such irregularities in foam distribution may lead to an irregular force or strain load on the casing component, which in can turn lead to deformations or deviations from the desired shape or curvature of the casing component, even though the outer shell itself may conform to the specification.
  • irregular foam distribution within the shell may not immediately result in a deformation of the casing component, but only after some time. If the deformation occurs only after several days or weeks, the defect will not be detected by a visual inspection of the cased device as it leaves the production line or factory, but will only be noticeable when at the point of sale or after delivery to the customer. Further, even if the irregular foam distribution is detected during production, e.g.
  • KR 2015 0049921 A from the prior art discloses a continuous foam molding facility to execute manufacturing processes of a synthetic resin foaming and molding product all at once, wherein a number of molds are mounted in a transfer device such as a conveyor, a turntable, or the like, and a heating device such as an injecting device, a molding and demolding device.
  • a transfer device such as a conveyor, a turntable, or the like
  • a heating device such as an injecting device, a molding and demolding device.
  • Non-contact temperature measurement can be realized by an optical thermometer by applying matte paint to the surface of a mold made of aluminum.
  • US 2017/0031330 A1 discloses an injection molding system including a state observation section observing, when injection molding is performed, physical-amounts relating to the injection molding that is being performed; a physical-amount data storage section storing the physical-amount data; a reward-conditions setting section setting reward condition for machine learning; a reward calculation section calculating a reward based on the physical-amount data and the reward conditions; an operating-conditions adjustment learning section performing machine learning of adjusting operating conditions based on the reward calculated by the reward calculation section, the operating conditions and the physical-amount data.
  • EP 1 615 152 A1 discloses a finite element method to analyze a foaming flow behavior of the foaming material by obtaining a flow velocity and a pressure by inputting the density as a function including a term of the elapsed time from the passage through an injection port to the foaming die and the thickness term and substituting a density calculated at a time in an equation of continuity and an equation of motion.
  • DE 10 2006 057772 A1 discloses a device with a container filled with a liquid dispersion.
  • a gas supply is induced for generating foam from the liquid dispersion and gas is controlled in the liquid dispersion.
  • a unit is provided for determining the level of the produced foam.
  • Two electrodes are provided for time resolved detection of the conductivity of the produced foam.
  • a video camera is provided for detecting the lamella size of the produced foam.
  • US 2016/0274561 A1 discloses a method of controlling a manufacturing process having a machine to form a material into a component.
  • the method comprises the steps of establishing an initial set of operating parameters for the machine, producing an initial component from the machine, inspecting the component to determine its acceptability relative to a desired component, determining a variation in the operating parameters to improve the acceptability of the component, effecting changes in the operating parameters and inspecting subsequent components to determine their acceptability.
  • US 2004/0059452 A1 discloses a wireless image processing method and device for utilization in combination with a machine vision system, wherein a wireless communicator delivers images to a host computer that can analyze the data and determine functionality to the manufacturing process.
  • US 2015/0102716 A1 which is considered the closest prior art, discloses a method for manufacturing a refrigerator appliance.
  • the method includes applying a polyurethane elastomer onto a surface of an inner liner of the refrigerator appliance and injecting a polyurethane foam into a cavity defined between an outer case of the refrigerator appliance and the inner liner.
  • the object of the invention is to provide a method for improving the production of a cased device such that rejection of casing components or entire cased devices can be successively reduced and the yield and efficiency of the production process successively increased.
  • the object of the invention is achieved through a method for improving the production of a cased device according to claim 1.
  • the invention is based on the recognition that in addition to the visual or thermographic inspection data of the casing component, additional data relating to the foam injection molding process itself can be used and correlated to obtain updated injection control data to improve the production process.
  • additional data relating to the foam injection molding process itself can be used and correlated to obtain updated injection control data to improve the production process.
  • the imaging of the casing component and analysis of the solid foam created within the casing component of the cased device is not just used to determine whether the casing component is still within specifications, but also to provide the basis for a feedback to the injection control data underlying the foam injection molding process.
  • the process itself can be improved the more imaging data there is.
  • the method according to the invention is for improving the production of a cased device.
  • a cased device in the sense of the present invention is any device which comprises a casing.
  • the casing of the device presents an outer casing.
  • the casing may also be only a part of the outer enclosure of the cased device.
  • a casing component of the cased device is produced.
  • the casing component of the cased device may be any component of the cased device in which an interior foam is arranged within a cavity formed by the casing component.
  • the casing component comprises a shell which forms the cavity.
  • the shell may be formed by any rigid material including metal and plastic.
  • the shell may be assembled from several shell components.
  • said production of the casing component comprises injecting a polymer mixture for creating a solid foam interior into a cavity, which cavity is formed by the shell of the casing component, which injecting is done by an injection apparatus.
  • said injecting is based on injection control data input to the injection apparatus.
  • Said injecting corresponds to the well-known reaction injection molding process also known as foam injection molding.
  • the injection control data may fully or partially, directly or indirectly determine the operation of the injection apparatus as it executes the injection of the polymer mixture and also other steps of the foam injection molding.
  • forming data for describing the injection process is recorded.
  • Such forming data may in principle be any kind of data recorded during or immediately after the injection process which is related to the foam injection molding process.
  • at least one image of the casing component is recorded.
  • the at least one image may cover the entire casing component or only a part thereof.
  • each of the at least one images may in itself be an image series or a video.
  • a prediction model for generating new injection control data for inputting to the injection apparatus is updated.
  • the prediction model is configured for generating new injection control data, which can subsequently be input to the injection apparatus, based on input provided to the prediction model, which in principle may be any kind of data.
  • the forming data, the at least one image and the injection control data are now used to update or adapt the prediction model and therefore how it generates new injection control data.
  • This new injection control data can then be used for an injection of the polymer mixture which is subsequent to the injection for which the associated injection control data is used to update the prediction model.
  • the casing component is assembled with cased device components - in other words other components of the cased device - to form the assembled cased device after the recording of the thermographic image.
  • the at least one image may in principle comprise any kind of image data.
  • the at least one image comprises a visual inspection of the casing component for detecting defects of the casing component.
  • the visual inspection may be within the visible spectrum.
  • the visual inspection may concern any kind of defects.
  • the visual inspection may concern the entire casing component or only a part of the casing component. It is preferred that the defects here referred to comprise deviations of the casing component from prescribed dimensional specifications. Alternatively or in addition, the defects here referred to may comprise deviations of the casing component from a prescribed surface contour.
  • the visual inspection is recorded after the casing component is assembled to form the assembled cased device.
  • the visual inspection of the assembled cased device is recorded for detecting defects of the assembled cased device.
  • the defects comprise deviations of the assembled cased device from prescribed dimensional specifications and/or deviations of the assembled cased device from a prescribed surface contour.
  • the recorded visual inspection may comprise a single image. It may also comprise a succession of images or a video.
  • the visual inspection comprises a stripe light scan of casing component, preferably of the assembled cased device.
  • the prediction model is also updated based on the visual inspection.
  • the at least one image comprises a thermographic image for determining a distribution of the solid foam interior in the cavity.
  • the thermographic image may in particular be an infrared image.
  • the thermographic image is based on residual heat generated by an exothermic foam creation reaction.
  • the distribution of the solid foam interior is determined based on the distribution of the residual heat within the cavity. This approach permits obtaining information about the state within the cavity with a camera that is placed outside the cavity. It is further preferred that the thermographic image is recorded before the visual inspection is recorded.
  • the solid foam interior may be any kind of solid foam and therefore consist of an arbitrary foam material.
  • the solid foam interior may be a polymer foam interior.
  • the solid foam interior is a polyurethane foam interior.
  • the solid foam interior may be a thermoplastic polyurethane foam interior or a thermosetting polyurethane foam interior.
  • Polyurethanes are an important component in major appliances which consumers use every day.
  • the most common use for polyurethanes in major appliances is rigid foams for refrigerator and freezer thermal insulation systems.
  • Rigid polyurethane foam can be a cost-effective material used to meet required energy ratings in consumer refrigerators and freezers.
  • the good thermal insulating properties of rigid polyurethane foams result from the combination of a fine, closed-cell foam structure and cell gases that are poor heat conductors.
  • the casing component may comprise an outer casing and an inner liner.
  • the shell may comprise the outer casing and the inner liner.
  • the outer casing may comprise a sheet metal or consist of sheet metal.
  • the inner liner may comprise polystyrene or consist of polystyrene. It is preferred that the cavity is formed between the outer casing and the inner liner.
  • the solid foam interior may act as both a structural and an insulating material.
  • the solid foam interior forms an adhesive bond with the casing component.
  • the solid foam interior may form an adhesive bond with the outer casing and the inner liner.
  • the solid foam interior may convey structural stability.
  • the component charge of the polymer mixture may be provided from any source and it may also be that there is no information about it other than specifications.
  • a preferred embodiment of the method is characterized in that a component charge of the polymer mixture is produced in a precursor production process based on recipe data at a precursor production facility and that during the precursor production process of the component charge precursor production data is recorded.
  • the component charge is a single charge of any component making up the polymer mixture used for the foam injection molding process.
  • the recipe data prescribes the formulation for the component charge, i.e. the specific ingredients and their proportion to be used for producing the component charge.
  • the prediction model is also updated based on the precursor production data and/or the recipe data. Thus, this additional data from an upstream production step can also be involved to further improve the prediction model.
  • a further preferred embodiment of the method is characterized in that the component charge is a polyisocyanate charge or a polyol charge.
  • Polyisocyanate and polyol may react to produce a polyurethane.
  • the component charge is suitable for forming the solid foam interior with the respective other reactant.
  • the precursor production data may be any data measured during the precursor production process and in some way connected to the production of the component charge.
  • the precursor production data comprises, in particular user-settable, precursor production settings which are input to a precursor production apparatus for controlling the precursor production process of the component charge.
  • the precursor production settings directly or indirectly determine the operation of the precursor production apparatus in the precursor production process.
  • the precursor production data comprises precursor measurement data measured during the precursor production process of the component charge.
  • this may be any kind of data measured in the context of the precursor production process of the component charge.
  • a preferred embodiment of the method is characterized in that the component charge of the polymer mixture is stored in precursor storage process and that during the precursor storage process of the component charge, precursor storage data is recorded. Thus, there is information on what the circumstances of storing the precursor charge were. It is further preferred that the prediction model is also updated based on the precursor storage data. The conditions during storage of the component charge as well as the duration of the storage of the component charge may affect the quality of the subsequent foam injection molding in a substantial way, for example by causing a premature deterioration of the component charge.
  • a further preferred embodiment of the method is characterized in that the prediction model comprises a correlation between correlation variables, which correlation variables comprise the injection control data, the forming data and the at least one image, preferably the thermographic image and/or the visual inspection.
  • the prediction model provides the ability to numerically, analytically or in any other, potentially approximate way determine one or more of the correlation variables as output of the prediction model based on one or more other correlation variables as input to the prediction model.
  • the prediction model may be a software, a part of a software or a data set, e.g. of parameters, based on which a software operates.
  • the prediction model may be executed by a single computer, by a group of computers or in a distributed or cloud computing environment.
  • the correlation variables also comprise the recipe data, the precursor production data, the precursor storage data and/or the charge properties data.
  • the prediction model is configured for generating new injection control data based on precursor storage data and/or precursor production data and/or precursor production data of the component charge of the polymer mixture which has been input to the prediction model. In this way, it is possible to obtain such injection control data that is advantageous, for example for reducing scrap, improving quality or making the process faster, and has been specifically calculated to take into account the peculiarities of the specific component charge and its product history so far.
  • the injection control data for the injection apparatus injecting the polymer mixture is generated by the prediction model based on the precursor storage data and/or the precursor production data and/or the charge properties data of a component charge of the injected polymer mixture.
  • the generated injection control data is actually applied in the foam injection molding process.
  • the prediction model generates updated recipe data and/or updated precursor production settings based on the correlation variables.
  • the updated recipe data and/or the updated precursor production settings provided are to the precursor production facility, in particular to the precursor production apparatus, for the production of a subsequent component charge.
  • the prediction model can not only improve the casing component by tuning the foam injection molding process, but can also provide updates to the upstream precursor production process in order to obtain more suitable component charges.
  • the prediction model may be updated based on an arbitrary mechanism.
  • a preferred embodiment of the method is characterized in that updating the prediction model comprises a numerical analysis of the correlation variables.
  • a further preferred embodiment of the method is characterized in that the injection control data comprises material output data, core temperature, mold temperature, material temperature, dosage pressure, hold time and/or pump output.
  • the forming data comprises ambient data, in particular temperature, air pressure and/or humidity. It is further preferred that the forming data comprises foam leakage data.
  • the foam leakage data may describe a foam amount that has leaked during the injection process and/or as a result of the injection process.
  • a preferred embodiment of the method is characterized in that the cased device is a home appliance.
  • the cased device is a refrigerator and the casing component is a refrigerator casing component.
  • the refrigerator casing component is a refrigerator door case or a refrigerator wall case.
  • the system shown in Fig. 1 concerns the production process of a cased device 1, which cased device 1 in the present case is a home appliance and in particular a refrigerator.
  • a casing component 2 of the cased device 1 is produced, which casing component 2 in the present case is a refrigerator door with a shell.
  • an injection apparatus 3 a polymer mixture 4 is injected into a cavity formed by the shell of the refrigerator door. This injection occurs as part of a foam injection molding process.
  • the operation of the injection apparatus 3 is controlled by injection control data 5.
  • forming data 6 is recorded to provide measurements for describing the injection process.
  • thermographic image 7 After the injection process, an image which is a thermographic image 7 is recorded by an infrared camera. Based on the recorded heat distribution, a distribution of the solid foam interior within the cavity of the casing component 2 can be determined.
  • the forming data 6, the thermographic image 7 and the injection control data 5 is provided to an analysis system 9 to update a prediction model 8 implemented as a software application and residing in the analysis system 9, which prediction model 8 configured to generate new injection control data 10 for inputting to the injection apparatus 3.
  • Such new injection control data 10 may in itself be incomplete and for example be modification information with respect to the injection control data 5, which thereby serves as a baseline.
  • thermographic image 7 In addition to the thermographic image 7 and after the casing component 2 has been assembled to become the cased device 1, a further image which is here a visual inspection 11 is recorded which involves performing a stripe light scan for detecting deviating surface contours as defects on the cased device 1.
  • a precursor production facility 13 produces a component charge 12, which here is a polyol charge, of the polymer mixture 4. This production is based on the one hand on recipe data 14 and on precursor production settings 15 which are input to a precursor production apparatus 16 of the precursor production facility 13. During the precursor production process, precursor production measurement data 18 is recorded, which forms precursor production data 17 together with the precursor production settings 15.
  • the component charge 12 Prior to the injection process, the component charge 12 is stored for some time. Precursor storage data 19 describing the precursor storage process, including storage time and ambient variables such as temperature, air pressure and humidity is recorded. Likewise, tests are conducted on the component charge 12 to measure and record charge properties data 20.
  • the visual inspection 11, the recipe data 14, the precursor storage data 19, the charge properties data 20 and the precursor production data 17 are also provided to the analysis system 6 for updating the prediction model 8 based on the visual inspection 11, the recipe data 14, the precursor storage data 19, the charge properties data 20 and the precursor production data 17.
  • the prediction model 8 is updated based on the continuing supply of the different data provided to the analysis system 6. In this way, correlations, dependencies and functional relationships between these correlation values may be identified and the prediction model 8 updated accordingly.
  • the prediction model 8 may provide new injection control data 10 which particularly suitable for e.g. avoiding defects under particular circumstances. For example, it may be determined by the prediction model 8 with the benefit of the information provided that for a component charge 12 stored under particular circumstances as shown by the precursor storage data 19, new injection control data 10 should be generated to adjust the foam injection molding process so as to avoid an irregular foam distribution. On the other hand, a component charge 12 with slightly different recipe data 14 may require different new injection control data 10 to avoid the same defect. Processing large amounts of the correlation values may help come to such insights e.g. by numerical analysis, which insights are then reflected in the prediction model 8. Beside the new injection control data 10, the prediction model 8 also provides updated recipe data 21 and updated precursor production settings 22, which are both provided to the precursor production facility 13 and in particular the precursor production apparatus 16 in order to improve the precursor production process for a subsequent component charge 12.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Artificial Intelligence (AREA)
  • Computer Vision & Pattern Recognition (AREA)
  • Evolutionary Computation (AREA)
  • Medical Informatics (AREA)
  • Software Systems (AREA)
  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Automation & Control Theory (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Molding Of Porous Articles (AREA)

Claims (14)

  1. Verfahren zur Verbesserung der Herstellung einer gehäusten Vorrichtung (1), wobei eine Gehäusekomponente (2) der gehäusten Vorrichtung (1) hergestellt wird, wobei die Gehäusekomponente (2) eine Hülle umfasst, wobei die Herstellung der Gehäusekomponente (2) ein Einspritzen eines Polymergemischs (4) zum Erzeugen eines Festschauminnenbereichs in einen Hohlraum umfasst, wobei der Hohlraum durch die Hülle der Gehäusekomponente (2) gebildet wird, wobei das Einspritzen durch eine Einspritzeinrichtung (3) erfolgt, und wobei das Einspritzen auf Einspritzsteuerungsdaten (5) basiert, die in die Einspritzeinrichtung (3) eingegeben werden, dadurch gekennzeichnet, dass während des Einspritzens des Polymergemischs (4) in den Hohlraum Bildungsdaten (6) zum Beschreiben des Einspritzprozesses aufgezeichnet werden, dass nach dem Einspritzen des Polymergemischs (4) in den Hohlraum mindestens ein Bild der Gehäusekomponente (2) aufgezeichnet wird, dass das mindestens eine Bild ein thermografisches Bild (7) zum Bestimmen einer Verteilung des Festschauminnenbereichs im Hohlraum umfasst, und dass basierend auf den Bildungsdaten (6), dem mindestens einen Bild und den Einspritzsteuerungsdaten (5) ein Vorhersagemodell (8) zum Generieren neuer Einspritzsteuerungsdaten (10) zum Eingeben in die Einspritzeinrichtung (3) aktualisiert wird.
  2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass das mindestens eine Bild eine Sichtprüfung (11) zum Erkennen von Fehlern der Gehäusekomponente (2) umfasst, wobei die Fehler vorzugsweise Abweichungen der Gehäusekomponente (2) von vorgegebenen Abmessungsspezifikationen und/oder Abweichungen der Gehäusekomponente (2) von einer vorgegebenen Oberflächenkontur umfassen.
  3. Verfahren nach Anspruch 2, dadurch gekennzeichnet, dass die Sichtprüfung (11) eine Streifenlichtabtastung der Gehäusekomponente (2) umfasst, und, dass das Vorhersagemodell (8) vorzugsweise auch basierend auf der Sichtprüfung (11) aktualisiert wird.
  4. Verfahren nach einem der Ansprüche 1 bis 3, dadurch gekennzeichnet, dass eine Komponentenfüllung (12) des Polymergemischs (4) in einem Vorläuferherstellungsprozess basierend auf Rezepturdaten (14) an einer Vorläuferherstellungsanlage (13) hergestellt wird, dass während der Vorläuferherstellungsprozesses der Komponentenfüllung (12) Vorläuferherstellungsdaten (17) aufgezeichnet werden, und, dass das Vorhersagemodell (8) vorzugsweise auch basierend auf den Vorläuferherstellungsdaten (17) und/oder den Rezepturdaten (14) aktualisiert wird.
  5. Verfahren nach Anspruch 4, dadurch gekennzeichnet, dass die Vorläuferherstellungsdaten (17) Vorläuferherstellungseinstellungen (15) umfassen, die zum Steuern des Vorläuferherstellungsprozesses der Komponentenfüllung (12) in eine Vorläuferherstellungseinrichtung (16) eingegeben werden.
  6. Verfahren nach Anspruch 4 oder 5, dadurch gekennzeichnet, dass die Komponentenfüllung (12) des Polymergemischs (4) in einem Vorläuferlagerungsprozess gelagert wird, dass während des Vorläuferlagerungsprozesses der Komponentenfüllung Vorläuferlagerungsdaten (19) aufgezeichnet werden, und, dass das Vorhersagemodell (8) vorzugsweise auch basierend auf den Vorläuferlagerungsdaten (19) aktualisiert wird.
  7. Verfahren nach einem der Ansprüche 4 bis 6, dadurch gekennzeichnet, dass Füllungseigenschaftsdaten (20) von der Komponentenfüllung (12) gemessen werden, und, dass das Vorhersagemodell (8) vorzugsweise auch basierend auf den Füllungseigenschaftsdaten (20) aktualisiert wird.
  8. Verfahren nach einem der Ansprüche 1 bis 7, dadurch gekennzeichnet, dass das Vorhersagemodell (8) eine Korrelation zwischen Korrelationsgrößen umfasst, wobei die Korrelationsgrößen die Einspritzsteuerungsdaten (5), die Bildungsdaten (6) und das mindestens eine Bild, vorzugsweise das thermografische Bild (7) und/oder die Sichtprüfung (11), die Rezepturdaten (14), die Vorläuferherstellungsdaten (17), die Vorläuferlagerungsdaten (19) und/oder die Füllungseigenschaftsdaten (20) umfassen, und, dass das Vorhersagemodell (8) insbesondere zum Generieren neuer Einspritzsteuerungsdaten (10) basierend auf den Vorläuferlagerungsdaten (19) und/oder den Vorläuferherstellungsdaten (17) und/oder den Füllungseigenschaftsdaten (20) der Komponentenfüllung (12) des Polymergemischs (4) ausgelegt ist, die in das Vorhersagemodell (8) eingegeben wurden.
  9. Verfahren nach Anspruch 8, dadurch gekennzeichnet, dass die Einspritzsteuerungsdaten (5) für die Einspritzeinrichtung (3), die das Polymergemisch (4) einspritzt, durch das Vorhersagemodell (8) basierend auf den Vorläuferlagerungsdaten (19) und/oder den Vorläuferherstellungsdaten (17) und/oder den Füllungseigenschaftsdaten (20) einer Komponentenfüllung (12) des eingespritzten Polymergemischs (4) generiert werden.
  10. Verfahren nach Anspruch 8 oder 9, dadurch gekennzeichnet, dass das Vorhersagemodell (8) aktualisierte Rezepturdaten (21) und/oder aktualisierte Vorläuferherstellungseinstellungen (22) basierend auf den Korrelationsgrößen generiert, und, dass die aktualisierten Rezepturdaten (21) und die aktualisierten Vorläuferherstellungseinstellungen (22) insbesondere für die Vorläuferherstellungsanlage (13), insbesondere für die Vorläuferherstellungseinrichtung (16) zur anschließenden Herstellung einer Komponentenfüllung (12) bereitgestellt werden.
  11. Verfahren nach einem der Ansprüche 8 bis 10, dadurch gekennzeichnet, dass das Aktualisieren des Vorhersagemodells (8) eine numerische Analyse der Korrelationsgrößen umfasst.
  12. Verfahren nach einem der Ansprüche 1 bis 11, dadurch gekennzeichnet, dass die Einspritzsteuerungsdaten (5) Materialausgabedaten, Kerntemperatur, Formtemperatur, Materialtemperatur, Dosierungsdruck, Haltezeit und/oder Pumpenleistung umfassen.
  13. Verfahren nach einem der Ansprüche 1 bis 12, dadurch gekennzeichnet, dass die Bildungsdaten (6) Umgebungsdaten, insbesondere Temperatur, Luftdruck und/oder Feuchtigkeit umfassen, und, dass die Bildungsdaten vorzugsweise Schaumaustrittsdaten umfassen.
  14. Verfahren nach einem der Ansprüche 1 bis 13, dadurch gekennzeichnet, dass die Vorrichtung (1) ein Haushaltsgerät, vorzugsweise ein Kühlschrank, ist, und die Gehäusekomponente (2) eine Kühlschrankgehäusekomponente ist, wobei die Kühlschrankgehäusekomponente vorzugsweise ein Kühlschranktürrahmen oder ein Kühlschrankwandrahmen ist.
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